Folding spa cover

ABSTRACT

A retractable, folding, insulating spa cover assembly with interconnected, plural, elongated, generally rectangular, panel members, the panel members being connected to each other along their longitudinal edges or sides by hinge members that act as gaskets to close the entire gap between adjoining panel members, wherein the hinge members alternate between the upper and lower surface of the panel members, such that the panel members are foldable into a vertical stack. Track members may be provided on opposing upper walls of the spa, with pins or roller members disposed on each end of the panel members such that the panel members slide laterally within the track members. The track members may each have a horizontal leg and a vertical leg, such the panel members remain in the track members when vertically stacked as well. In an alternative embodiment, vertically oriented roller conveyor members may be positioned beside the spa.

This patent application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/962,324, filed Jul. 27, 2007, the disclosure of which is herein incorporated by reference.

BACKGROUND OF THE INVENTION

This invention relates generally to the field of removable covers that prevent water and debris from entering spa tubs, hot tubs or the like, and which insulate to prevent heat loss when the tubs are not in use, and more particularly relate to such covers that are provided in multiple parts.

Spa tubs, hot tubs or the like, to be referred to herein collectively as spas, are popular in home, hotel and rehabilitation settings and are used for recreation, relaxation and therapy. The spas typically contain a quantity of heated water that is recycled through water jets, and may vary in shape from generally rectangular to generally round. The spas are usually sized to accommodate four to six people at one time, although smaller and larger spas are also available. Often the spas are located outdoors on patios or porches. Because the water is usually maintained at an elevated temperature even when the spas are not in use, insulated covers are provided to limit heat loss. The covers also prevent debris and rain water from entering the spa water.

The typical known insulated covers are structured in large panel form, such that usually one, two or three panels are placed on top of the spa, with multiple panel covers being composed of separate and distinct members that are not connected. The cover panels are usually several inches thick for insulation and structural purposes, and may comprise for example a main body of insulating material, such as a polymer foam, encased within a waterproof outer layer of sheet material, such as HDPE or other plastic. Though not excessively heavy, they are of significant weight, and the large size of the cover panels makes them unwieldy in handling, such that removal and replacement by children or older adults may be difficult. In addition, the large size of the panel members makes it difficult to store them unobtrusively when the spa is in use.

It is an object of this invention to provide a spa cover that is composed of a plurality of slat-like, rectangular panel members, such that removal and replacement of the members is easier, with the slat-like panel members connected in a hinged manner so as to prevent passage of debris and water between the panel members. It is a further object to provide such a spa cover that is retractable in a folding manner, such that the individual panels comprising the cover can be stacked vertically beside the spa without interfering with the enjoyment of the spa. It is a further object to provide such a spa cover with the hinge members being connected to adjoining panel members on upper and lower surfaces in alternating manner, such that the panels may be stacked in a pleated manner. It is a further object to provide an embodiment wherein track or guide members are provided on the spa such that the individual panel members are received within the opposing track members in a manner that allows the panel members to be retracted and advanced along the track to uncover and cover the spa. It is a further object to provide an embodiment where generally vertical roller conveyor members are provided at the side of the spas to assist in stacking and unstacking the vertical stack of panel members when the cover panels are removed from or placed onto the spa.

SUMMARY OF THE INVENTION

The invention is a removable or retractable, folding, insulating spa cover or spa cover assembly comprising a spa cover of plural, elongated, generally rectangular, slat-like, insulated, panel members, the panel members being connected to each other along their longitudinal edges by hinge means for hingedly joining adjacent panel members. The hinge means preferably act as seals to cover the entire gap between adjoining panel members, such that water and debris cannot pass between the panel members and into the spa, and such that the thermal insulating properties of the cover are maximized. The hinging means may comprise hinge members affixed in accordion-style alternating manner along the upper and lower surfaces of the panel members, such that for a given panel member one hinge means will be at the upper surface and the other hinge means will be at the lower surface. In this manner the panel members are foldable into a vertical stack one atop the other when removed from the spa. Track or guide members may be provided on opposing upper walls of the spa, with pins or roller members disposed on each end of the panel members such that the panel members are received by the track members in a manner that allows them to slide laterally along the track members. The track members may each also comprise both a horizontal leg extending along the top of the spa and a vertical leg extending down the side of the spa, such that the panel members are retained by the vertical leg when displaced into the vertical stack during use of the spa. In an alternative embodiment, manual or powered drive members for translating the panel members may be provided to move the panel members along the track members in order to cover and uncover the spa. In an alternative embodiment, two or more generally vertically oriented roller conveyor members may be positioned adjacent a side of the spa, the roller conveyor members each having roller members on the side and top so as to reduce friction and drag when the panel members are removed from the spa or placed onto the spa.

In alternative language, a folding spa cover is presented comprising a plurality of elongated, substantially rectangular, interconnected, insulating panel members, the majority of said panel members being interior panel embers and two of said panel members being end panel members, each of the panel members having an upper surface and a lower surface, wherein the panel members are joined to each other with hinge members in alternating manner such that the panel members are foldable in an accordion-style manner into a vertical stack, such that each individual interior panel member is joined to a first adjacent panel member at or adjacent the upper surface and to a second opposite adjacent panel member at or adjacent the lower surface.

In alternative language, a retractable folding spa cover assembly is mounted onto a spa having side walls and a generally horizontal upper surface, said assembly comprising:

a plurality of elongated, substantially rectangular, interconnected, insulating panel members, the majority of said panel members being interior panel embers and two of said panel members being end panel members, each of the panel members having ends, an upper surface and a lower surface, wherein the panel members are joined to each other with hinge members in alternating manner such that the panel members are foldable in an accordion-style manner into a vertical stack, such that each individual interior panel member is joined to a first adjacent panel member at or adjacent the upper surface and to a second opposite adjacent panel member at or adjacent the lower surface;

a pair of generally horizontal, opposing track members atop the walls of said spa, said track members each comprising a slot receiving and retaining said panel members whereby said panel members can be moved horizontally within said track members.

In alternative language, a retractable folding spa cover assembly is presented in combination with a spa having side walls and a generally horizontal upper surface, said assembly comprising:

a plurality of elongated, substantially rectangular, interconnected, insulating panel members, the majority of said panel members being interior panel embers and two of said panel members being end panel members, each of the panel members having ends, an upper surface and a lower surface, wherein the panel members are joined to each other with hinge members in alternating manner such that the panel members are foldable in an accordion-style manner into a vertical stack, such that each individual interior panel member is joined to a first adjacent panel member at or adjacent the upper surface and to a second opposite adjacent panel member at or adjacent the lower surface;

at least two generally vertically oriented roller conveyor members positioned externally adjacent a side wall of the spa, said roller conveyor members each comprising an upstanding body member having a plurality of roller members disposed thereon and facing away from said spa side wall to define a rollway for said panel members;

whereby said roller members reduce friction and drag when the panel members are pulled from the vertical stack back onto the upper surface of said spa.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial perspective view of one embodiment of the retractable folding spa cover in position on top of a spa.

FIG. 2 is a partial perspective view showing the spa cover of FIG. 1 in an intermediate position during the covering or uncovering of the spa.

FIG. 3 is a partial perspective view of an embodiment of the invention, again shown in an intermediate position during the covering or uncovering of the spa, wherein the track members extend vertically as well as horizontally.

FIG. 4 is a partial side view of an embodiment of the invention, showing a vertically oriented roller conveyor member provided adjacent the spa and the vertical stack of panel members.

DETAILED DESCRIPTION OF THE INVENTION

With reference to the drawings, the invention will now be described in detail with regard for the best mode and the preferred embodiment. In general, the invention is a removable or retractable, folding, insulating spa cover presenting a horizontally extending coverage area, the spa cover comprising a plural number of elongated, slat-like, interconnected, panel members capable of being folded and positioned in a vertical stack of relatively small footprint when the spa is in use.

The spa cover 10 comprises a plural number of insulating panel members 30, the majority of the panel members 30 being interior panel members and two of said panel members 30 being end panel members. The panel members 30 are elongated and generally rectangular in shape, such that the panel members 30 comprise a number of slat-like elements. When in use to cover the spa 20, the individual panel members 30 are aligned laterally in a generally co-planar orientation, and adjacent panel members 30 are connected in accordion-style hinged manner along their longitudinal sides to form the spa cover 10, as shown in FIG. 1. The panel members 30 are preferably composed of an insulating polymer foam material encased within a waterproof polymer sheet material, the sheet material forming an envelope to fully encase the foam, although it is contemplated to form the panel members 30 of other material having properties capable of performing the necessary functions. In known manner, bracing or support members may be utilized internally or externally to increase rigidity of the elongated panel members 30 when the stiffness of the insulating material is not sufficient to preclude excessive flexing when the panel members 30 are positioned atop and spanning the spa 20.

Hinge means for connecting adjacent panel members 30 along the longitudinal sides in an accordion-style manner are provided such that each of the panel members 30 is foldable onto an adjacent panel member 30 to form a vertical stack, as shown in FIGS. 3 and 4. Hinge means may comprise hinge members 40, such as for example elongated strips of flexible plastic sheeting, or the material covering panel members 30 may be stitched or bonded together. The hinge members 40 are positioned alternately relative to the upper and lower surfaces of the panel members 30, such that each interior individual panel member 30 is joined to a first adjacent panel member 30 at or adjacent the upper surface and to a second opposite adjacent panel member 30 at or adjacent the lower surface, upper and lower surfaces being defined herein as their relative orientations when the spa cover 10 is in place atop the spa 20. In this manner all of the interconnected panel members 30 can be folded into a single vertical stack of relatively small footprint, as shown in FIGS. 3 and 4. The panel members 30 are relatively narrow in width, such that the width of the vertical stack is minimized. Most preferably, the hinge members 40 are formed of a waterproof, flexible sheet material that acts as a gasket or seal, such that with the hinge members 40 extending the full length of the panel members 30, the gaps between the adjoining panel members 30 are sealed or covered by the hinge members 40 to preclude passage of water and debris into the spa 20, as well as to provide a more complete thermal barrier to heat loss. The dimensions of the panel members 30 are not critical, but for purposes of providing an example only, it has been found that suitable dimensions for each panel member 30 may be between about 1 to 3 inches in thickness and between about 6 to 18 inches in width, with the length and number of panel members 30 being determined by the dimensions of the spa 20 being covered.

While the spa cover 10 as described may be placed directly atop the walls of the spa 20 and removed and replaced manually as needed, track members 60 may be provided to guide the panel members 30. Opposing track members 60 are formed as an integral part of the spa structure during or are mounted atop opposing walls of the spa 20, such as for example with mounting brackets 70 as shown in FIG. 1. The track members 60 define a means for guiding and retaining the panel members 30, and may be generally C-shaped in cross-section with the longitudinal slot being sized large enough to receive the ends of the panel members 30 themselves, but most preferably a smaller slot is provided in the track members 60 and the panel members 30 are provided on each end with pins, wheels, rollers or similar guide members 50 that are received within the track members 60. As shown in FIG. 2, one suitable embodiment for the guide members 50 is that of a headed post. Alternative configurations from that illustrated for the track members 60 and roller members 60 that accomplish the stated purposes are possible, such as for example a U-shaped track member 50 with the slot oriented toward the top, or an L-shaped track member 50 that bounds the outer ends of the panel members 30 or guide members 50.

In one embodiment, shown in FIGS. 1 and 2, the track members 60 are horizontally disposed and the tracks 60 are open on at least one end such that the panel members 30 may be removed from the track members 60 and folded into a vertical stack, as shown in FIG. 2. Covering the spa 20 is accomplished by reversing this action, the guide members 50 of the uppermost panel member 30 from the vertical stack being first inserted into the track members 60 and then each successive panel member 30 from the stack being inserted in order. In an alternative embodiment, as shown in FIG. 3, the track members 60 extend horizontally along the top of the spa 20 and vertically adjacent the side of the spa 20, such that the panel members 30 are not removed from the track members 60 during the uncovering and covering operation. The vertical legs of the track members 60 are positioned sufficient distance from the side of the spa 20 such that the panel members 30 are able to clear the spa 20 during the transition from horizontal to vertical movement.

In still another embodiment, as shown in FIG. 4, two or more generally vertically oriented roller conveyor members 80 are externally positioned adjacent a side of the spa, the roller conveyor members 80 each comprising an upstanding body member 83 defining a shoulder 84 facing away from the spa 20. Each of the body members 83 has a plurality of roller members 82 generally linearly disposed along at least the shoulder 83, but preferably also along the top and side, of the body member 83 that define a rollway facing away from the spa 20. The roller conveyor members 80 are positioned between the spa 20 and the vertical stack of panel members 30 and serve to reduce friction and drag when the panel members 30 are pulled from the vertical stack back onto the upper surface of the spa 20. The roller conveyor members 80 may be free-standing or secured to the spa 20, but preferably are provided with thin footer members 81 that can be positioned beneath the spa 20 such that the weight of the spa 20 maintains the roller conveyor members 80 in place. The shoulder 84 of the roller conveyor members 80 is preferably curved as shown, but may also be provided in a beveled or right-angled configuration.

It is further contemplated that manual or powered drive means (not shown) for translating or repositioning the panel members 30 between the covering and uncovering orientations, such as a hand crank, an electric motor, a hydraulic device or the like, may be provided to move the panel members 30 within the track members 60, such that covering and uncovering the spa 20 is more easily accomplished. Such drive means are well known, for example, in the window shade or panel door arts, and the mechanisms are readily adaptable to the spa cover as described herein.

It is also contemplated that equivalents and substitutions for certain elements set forth above may be obvious to those of ordinary skill in the art, and therefore the true definition and scope of the invention is to be as set forth in the following claims. 

1. A folding spa cover comprising a plurality of elongated, substantially rectangular, interconnected, insulating panel members, the majority of said panel members being interior panel embers and two of said panel members being end panel members, each of the panel members having an upper surface and a lower surface, wherein the panel members are joined to each other with hinge members in alternating manner such that the panel members are foldable in an accordion-style manner into a vertical stack, such that each individual interior panel member is joined to a first adjacent panel member at or adjacent the upper surface and to a second opposite adjacent panel member at or adjacent the lower surface.
 2. The spa cover of claim 1, wherein said hinge members extend substantially the full length of said panel members.
 3. The spa cover of claim 2, wherein said hinge members are waterproof so as to define a barrier between said panel members.
 4. The spa cover of claim 1, wherein said panel members are less than approximately 18 inches in width.
 5. A retractable folding spa cover assembly mounted onto a spa having side walls and a generally horizontal upper surface, said assembly comprising: a plurality of elongated, substantially rectangular, interconnected, insulating panel members, the majority of said panel members being interior panel embers and two of said panel members being end panel members, each of the panel members having ends, an upper surface and a lower surface, wherein the panel members are joined to each other with hinge members in alternating manner such that the panel members are foldable in an accordion-style manner into a vertical stack, such that each individual interior panel member is joined to a first adjacent panel member at or adjacent the upper surface and to a second opposite adjacent panel member at or adjacent the lower surface; a pair of generally horizontal, opposing track members atop the walls of said spa, said track members each comprising a slot receiving and retaining said panel members whereby said panel members can be moved horizontally within said track members.
 6. The assembly of claim 5, further comprising guide members mounted on said ends of said panel members, wherein said guide members are received within said slots of said track members.
 7. The assembly of claim 6, wherein said guide members are chosen from the group of guide members consisting of pins, wheels and rollers.
 8. The assembly of claim 5, said track members extending vertically downward adjacent said spa side walls, whereby said panel members can also be moved vertically within said track members.
 9. The assembly of claim 8, further comprising guide members mounted on said ends of said panel members, wherein said guide members are received within said slots of said track members.
 10. The assembly of claim 9, wherein said guide members are chosen from the group of guide members consisting of pins, wheels and rollers.
 11. A retractable folding spa cover assembly in combination with a spa having side walls and a generally horizontal upper surface, said assembly comprising: a plurality of elongated, substantially rectangular, interconnected, insulating panel members, the majority of said panel members being interior panel embers and two of said panel members being end panel members, each of the panel members having ends, an upper surface and a lower surface, wherein the panel members are joined to each other with hinge members in alternating manner such that the panel members are foldable in an accordion-style manner into a vertical stack, such that each individual interior panel member is joined to a first adjacent panel member at or adjacent the upper surface and to a second opposite adjacent panel member at or adjacent the lower surface; at least two generally vertically oriented roller conveyor members positioned externally adjacent a side wall of the spa, said roller conveyor members each comprising an upstanding body member having a plurality of roller members disposed thereon and facing away from said spa side wall to define a rollway for said panel members; whereby said roller members reduce friction and drag when the panel members are pulled from the vertical stack back onto the upper surface of said spa.
 12. The assembly of claim 11, wherein said body members comprise a shoulder.
 13. The assembly of claim 12, wherein said shoulder is curved.
 14. The assembly of claim 12, wherein said shoulder is beveled.
 15. The assembly of claim 12, wherein said shoulder is right-angled.
 16. The assembly of claim 11, wherein said roller conveyor members further comprise footer members disposed beneath sad spa.
 17. The assembly of claim 11, wherein said hinge members extend substantially the full length of said panel members.
 18. The assembly of claim 17, wherein said hinge members are waterproof so as to define a barrier between said panel members.
 19. The assembly of claim 11, wherein said panel members are less than approximately 18 inches in width. 